Connector housings, use of, and method therefor

ABSTRACT

A method of making a connector assembly includes attaching two stamped housing sections together to form a connector housing having a housing groove with a groove bottom and two side walls and providing the connector housings with a spring used as a mechanical connector and/or as an electrical connector for numerous applications and across numerous industries. The groove geometries can easily be altered using different stamping dies.

CROSS-REFERENCE TO RELATED APPLICATION

This is a continuation application of co-pending application Ser. No.14/990,388, filed Jan. 7, 2016, which is a divisional application ofapplication Ser. No. 14/025,682, filed Sep. 12, 2013, now U.S. Pat. No.9,284,970, which is a regular application of provisional applicationSer. No. 61/701,404, filed Sep. 14, 2012, the contents of which areexpressly incorporated herein by reference.

FIELD OF ART

The present disclosure generally relates to connector housings for usewith a spring and more particularly to connector housings made fromstamped housing sections, stamped housing sections as part of amechanical connector, as part of an electrical connector, in a medicalapplication, and as methods for forming and using the stamped housingsections.

BACKGROUND

Implantable stackable lead connectors to date consist of a series ofmachined housings, also referred to as conductive contacts, separated bysealing members and wherein a spring contact is held in a groove definedat least in part by each machined housing section. Due to toleranceconcerns and critical dimension constraints, the housing components mayneed to be precision machined, resulting in a high cost connector.Furthermore, as the size of the connectors decrease, the housings becomevery difficult to machine. Exemplary implantable medical connectors arediscussed in U.S. Pat. No. 8,437,855, the contents of which areexpressly incorporated herein by reference for purposes of generallydisclosing IMDs and in-line connectors used with IMD and components forforming or making in-line connectors.

Connectors are also known for use as mechanical fasteners, as latchingconnectors, as holding connectors and as locking connectors. Theseconnectors typically have a housing with a bore and a pin either with orwithout a pin groove. A spring is placed in the groove, either of thehousing or the pin, for forming a connection between the pin and thehousing, which can be a holding connection type, a latching connectiontype in which the pin is allowed to be removed from the housing, or alocking connection type in which the pin is not allowed to be removedfrom the housing unless the connector, such as the spring, is destroyed.When the housing and the pin are coupled to an electrical source or nodeto pass current or electrical signals there-across, the connector canalso carry current and functions as an electrical connector. Exemplaryconnectors are disclosed in U.S. Pat. No. 4,678,210; 5,082,390;5,411,348; and 8,297,662.

SUMMARY

Aspects of the present disclosure include a stackable connector withspring contact housings formed from stamped components to achieve lowmanufacturing costs, reduced connector length, reduced stress and chanceof misorientation of the spring contact when installed into the housing.The connector also has testing capabilities to confirm properperformance prior to completing assembly of the housing.

Due to the nature of stamped components, the housing components may bemade with very consistent dimensions and thinner when compared tomachined housings, which may reduce the overall length of the connectorand potentially reduce the size of the implantable device.

The multi-piece housings can allow the spring contacts to be installedwithin the housing assemblies with reduced deflection, stress, ormisorientation. Furthermore, multi-piece housings allow for properplacement and performance of spring contacts within the multi-piecehousings to be tested, adjusted, and confirmed before the housing iscompletely assembled.

A further feature of the present disclosure is an in-line series ofstackable contact assemblies and sealing members, each contact assemblycomprising a housing and a spring contact, the housing being formed fromat least one stamped component being joined to another component andforming a groove in which the spring contact is retained.

The connector whereby the housing can be formed from two identicalstamped components. In other examples, the two stamped housing sectionsare not identical.

The connector whereby the components that form the housing can be joinedtogether by welding, fasteners, or mechanically linking.

The connector whereby the housing can have an exterior groove instead ofan interior groove.

The connector wherein the exterior groove can be used to retain anelectrical lead.

The connector whereby the groove can be used for linear positioning ofcomponents within the connector.

The connector whereby the spring contact can be a canted coil spring, agarter spring, a cantilever spring, or a ribbon spring.

Another feature of the present disclosure is a method of testing theperformance of a spring contact of a connector. The method can comprisethe step of obtaining an in-line series of stackable contact assembliesand sealing members, each contact assembly comprising a housing and aspring contact, the housing being formed from at least one stampedcomponent being joined to another component and forming a groove inwhich the spring contact is retained, prior to complete assembly of thehousing by holding the components that form the housing together withthe spring contact installed in the housing and inserting a lead to findinsertion, removal, and frictional forces, and electrical performance.

Yet a still further feature of the present disclosure is a connectorassembly comprising a connector housing comprising a first housingsection attached to a second housing and defining an interior cavitywith a housing groove comprising a groove bottom and two sidewalls. Thefirst housing section can comprise a flange with a first side and saidsecond housing section comprising a flange with a first side and whereinsaid first sides of the two flanges abut one another along a seam; andwherein each of said first housing section and said second housingsection comprising an enlarged projection comprising an openingextending outwardly of the flange, said enlarged projection of eachforming at least part of the groove bottom and at least part of one ofthe sidewalls and wherein the openings of the two enlarged projectionsdefining a common bore.

Yet another feature of the present disclosure is a connector assemblyhaving at least one housing section formed by stamping. The connectorassembly can comprise a connector housing comprising a first housingsection attached to a second housing and defining an interior cavitywith a housing groove comprising a groove bottom and two sidewalls; saidfirst housing section comprising a flange with a first side, an enlargedprojection comprising an opening extending outwardly of the flange andforming at least part of the groove housing and at least part of one ofthe sidewalls and said second housing section comprising a flange with afirst side and an opening and wherein said first sides of the twoflanges abut one another along a seam. The assembly wherein the openingsof the two housing sections defining a common bore and wherein at leastone of the two housing sections has a curved section formed by stamping.

The connector assembly wherein both housing sections are formed from ablank in a stamping process.

The connector assembly wherein the flange of the first housing sectioncan comprise a tab projecting into an open passage on the flange of thesecond housing section.

The connector assembly wherein the two flanges form an interfacetherebetween and wherein the interface can have a weld.

The connector assembly can further comprise a canted coil spring locatedin the housing groove.

The connector assembly wherein the canted coil spring has a smallerinside diameter than diameters of the two openings defining the commonbore.

The connector assembly can further comprise a pin projecting through thecommon bore.

The connector assembly can further comprise a seal element having a borewith a seal lip, said seal element abutting the connector housing andsealingly located inside a header of an implantable medical device.

The connector can further comprise a second connector housing abuttingthe seal element and a second seal element abutting the second connectorhousing; and wherein said second connector housing has a canted coilspring located therein.

A still yet further features of the present disclosure is a connectorassembly comprising a first stamped housing section having an upperflange, a skirt section, and a lower flange comprising an openingattached to a second stamped housing forming a connector housing, saidsecond stamped housing comprising an upper flange, a skirt section, anda lower flange comprising an opening and wherein said openings defininga common bore. An interface is formed at the two upper flanges where thetwo housing sections attach. An interior cavity is defined by the twohousing section having a housing groove comprising a groove bottom andtwo sidewalls with a canted coil spring disposed in the housing groove;and wherein each of said first housing section and said second housingsection comprising an enlarged projection extending outwardly of theflange.

The connector assembly wherein the flange of the first housing sectioncan comprise a tab projecting into an open passage on the flange of thesecond housing section.

The connector assembly wherein the interface can have a weld.

The connector assembly wherein the opening of the first housing sectiondefines a plane and wherein the groove bottom can be tapered relative tothe plane.

The connector assembly wherein the opening of the first housing sectiondefines a plane and wherein the groove bottom can be orthogonal to theplane.

The connector assembly can further comprise a pin projecting through thecommon bore.

The connector assembly can further comprise a header attached to a canhousing of an implantable medical device, and wherein the connectorhousing is disposed inside the header adjacent a seal element having abore aligned with the common bore.

The connector assembly wherein said first housing section and saidsecond housing section are identical.

Yet another feature of the present disclosure is a method for making aconnector housing comprising stamping a first housing section, saidfirst housing section comprising an upper flange, a skirt section, and alower flange comprising an opening and stamping a second housingsection, said second housing section comprising an upper flange, a skirtsection, and a lower flange comprising an opening. The method furthercomprises attaching said first housing section to said second housingsection by abutting said two upper flanges to form a connector housingcomprising a common bore and a housing groove comprising a groove bottomand two side walls and placing a canted coil spring inside said housinggroove.

The method wherein said canted coil spring can be placed in contact withsaid first housing section before said attaching step.

The method can further comprise the step of placing said connectorhousing in contact with a seal element and into a header of animplantable medical device.

The method can further comprise placing said connector housing incontact with a seal element and into an encapsulation layer to form anencapsulated stack.

DESCRIPTION OF DRAWINGS

These and other features and advantages of the present device, system,and method will become appreciated as the same becomes better understoodwith reference to the specification, claims and appended drawingswherein:

FIGS. 1A-1B show a stamped housing half or section in perspective andside views, respectively.

FIG. 1C shows two housing halves connected together to form a connectorhousing, with

FIG. 1D showing the same connector housing with a spring element.

FIG. 1E shows the connector housing of FIG. 1D with a pin or shaftdisposed inside the bore.

FIGS. 2A-2B show an alternative housing section in perspective and sideviews, respectively.

FIG. 2C shows two housing halves of FIG. 2A connected together to form aconnector housing.

FIGS. 3A-3B show an alternative housing section in perspective and sideviews, respectively.

FIG. 3C shows two housing halves of FIG. 3A connected together to form aconnector housing.

FIGS. 4A-4B show an alternative housing section in perspective and sideviews, respectively.

FIG. 4C shows two housing halves of FIG. 4A connected together to form aconnector housing.

FIGS. 5A-5B show an alternative housing section in perspective and sideviews, respectively.

FIG. 5C shows two housing halves of FIG. 5A connected together to form aconnector housing.

FIGS. 6A and 6B show an alternative housing section in perspective andcross-sectional side views, respectively.

FIG. 7 shows a cross-sectional side view of an alternative connectorhousing having a spring element in a spring groove.

FIG. 8 shows a cross-sectional side view of an alternative connectorhousing having a spring element in an exterior spring groove.

FIG. 9A shows an implantable medical device with an in-line connectorstack located inside a header.

FIG. 9B is an enlarged view of the header of FIG. 9A with the in-lineconnector stack.

FIG. 10A is a partial elevation and cross-sectional side view of anin-line connector stack located inside an encapsulation layer.

FIG. 10B is an end view of FIG. 10A taken along line 10B-10B.

FIGS. 10C and 10D are enlarged views of the components of FIG. 10A.

FIG. 11A is a perspective view of an in-line connector stack outside ofa header and without an encapsulation layer.

FIG. 11B is an enlarged view of FIG. 11A to show the connection of aconductor lead to one of the conductive contact elements.

DETAILED DESCRIPTION

The detailed description set forth below in connection with the appendeddrawings is intended as a description of the presently preferredembodiments of stamped housing sections for use in various connectorapplications provided in accordance with aspects of the present device,system, and method and is not intended to represent the only forms inwhich the present device, system, and method may be constructed orutilized. The description sets forth the features and the steps forconstructing and using the embodiments of the present device, system,and method in connection with the illustrated embodiments. It is to beunderstood, however, that the same or equivalent functions andstructures may be accomplished by different embodiments that are alsointended to be encompassed within the spirit and scope of the presentdisclosure. As denoted elsewhere herein, like element numbers areintended to indicate like or similar elements or features.

With reference now to FIG. 1A, a schematic perspective view of a housingsection 100 is shown, which has a housing body 102 having an outerperimeter 104 and a bore 106 with an inside diameter 108. As furtherdiscussed below with reference to FIG. 1C, the housing section 100 isconfigured to cooperate with another housing section 100 to form aconnector housing have a groove for receiving a spring. In one example,the bore 106 is generally round for receiving a round pin or a shaft, asfurther discussed below. In other examples, the bore 106 can embodyother shapes, such as square or oval for receiving a similarly shapedpin. The outer perimeter 104 can have the same or different shape as theshape of the bore 106. For example, the bore 106 can be round while theouter perimeter 104 is generally square. As shown, the outer perimeter104 and the bore 106 both have a round shape.

The housing section 100 may be made using a coining process, which is acold working process similar to forging, except the latter usually takesplace at elevated temperatures. A die or multiple dies may be used in acoining process to first cut a blank and then shaping the blank into arefined shape, which can optionally further be machined or laser treatedto further modify the final shapes and tolerances. The die or dies usedto shape the blank may have different shapes and contours for forming adifferent shaped housing section. Generally speaking, the shaped housingsection can be described as a negative image of the die or dies. A greatdeal of force is used to plastically deform a blank or work piece. Inone example, a hydraulic actuated press is used to supply the workingpressure. In other examples, a gear driven press or a mechanical pressmay be used to supply the working pressure. Coining is similar tostamping with the difference primarily being the working force orpressure. Unless the context indicates otherwise, coining and stampingfor purposes of the present disclosure are used synonymously.

Blank materials usable as the starting point for forming the disclosedhousing section 100 may be made from any number of conductive metals.Examples of metals that are capable of conducting current include steel,stainless steel, copper, and gold. Additionally, stainless steel type316L, MP35N, platinum-iridium, titanium and others may be used.Alternatively, the material can be conventional medically implantablegrade material with noble metal coatings, such as platinum overstainless steel. By coating a non-noble metal element with a noblemetal, the more desirable conductive and corrosion resistant propertiesof the noble metal are married with the significantly lower cost ofnon-noble metals such as high-strength nickel alloys and stainlesssteel. Thus, the stamped housing section 100 may be understood to bemade from a single metal material or a multi-layer metal material withthe latter having a base metal layer and one or more cladding or platingover-layers. For certain connector applications, plastic injectionmolding may also be employed to form the stamped housing and thenproviding a path through the plastic housing to terminate an electricallead to the canted coil spring. For pure mechanical applications withoutcurrent or signal carrying capability, two injection molded housingsections 100 may be joined with a canted coil spring located in betweento form a connector housing.

As shown, the housing section 100 comprises an upper flange 110, a skirtsection 112, and a lower flange 114. The upper flange 110 may begenerally planar, as shown in FIG. 7, or may have a curved surface, asshown in FIG. 1B. In one example, the upper flange 110 has a generallyflat or planar section 110 a with a tapered outwardly section 110 btowards the perimeter 104 and a tapered inwardly section 110 c, towardsthe bore 106. As shown with reference to FIG. 1C, the tapered inwardlysection 110 c flows into or is joined with the skirt section 112.Relative to a planar surface 116 defined by the bore 106, the skirtsection 112 is tapered. The taper may have a single slope or a curve. Inanother example, the skirt section 112 is generally orthogonal to theplanar surface 116 defined by the bore 106. The skirt section 112extends from the tapered inwardly section 110 c in a sloped or slantedmanner. In another example, the skirt section 112 forms a right anglewith the tapered inwardly section 110 c. The inside or inner most partof the upper flange 110 defines an inner perimeter 118 for the recessedspace 120 of the housing section 100, which is bounded in part by theskirt section 112 and the lower flange 114. The recessed space 120 isconfigured to accommodate a spring, as further discussed below. Thehousing section has a first side or operative side 90, such as foraccommodating a spring, and a second side or non-operative side 92.However, in some applications, the second side 92 can also be anoperative side for forming an external groove, such as that shown inFIG. 8. With reference to FIG. 1C, the first side or operative side 90of two housing sections 100 are configured to contact to form aconnector housing 130 having an interior cavity 132. The connectorhousing 130, which can be conductive when selecting appropriateconductive metallic material or a combination of materials, may bereferred to an a conductive contact element, such as when used incombination with an in-line header connector as further discussed belowwith reference to FIGS. 9A-11B. The second or non-operative 92 side faceaway from the interior cavity 132 but can contact another housingsection 100 when stacking a plurality of housing sections 100 (notshown) in a stack with all housing sections facing the same direction,such as for packaging or shipping.

In one example, the blank for forming the housing section 100, andtherefore the housing section, has a generally constant thickness, whichcan be sized or selected depending on the material hardness and the typeof connector application to be used, such as for a heavy duty highinsertion and/or removal force applications, for a mechanical connector,for an electrical connector, etc. In other examples, the thickness canvary to allow for bending and shaping the contour of the housing section100. By forming the housing section using a stamping process rather thanmachining the housing from a metal block, consistent housing dimensionsand thinner sections can be obtained, which can reduce the overalllength or size of a completed product, such as a the overall size of anin-line connector stack, and reduce manufacturing costs.

As shown, the upper flange 110 has two tabs 120 having ends 120 aprojecting away from the bore 106 and two open passages 122. The tabs120 may be formed by creating or making a three-sided cut on the flange110 and then bending the material away from the bore 106. The two openpassages 122 may be formed by completely punching through the surfacelayer of the flange. The opening of the two open passages 122 should besized and shaped to receive the corresponding tabs 120, as shown withreference to FIG. 1C and further discussed below. In one example, thetwo tabs 120, when bent, have wall surfaces that are generally parallelto one another. In another example, the tabs slightly converge towardsone another or slightly away from one another so that when they projectin the corresponding open passages 122, the surfaces form interferenceor snap fit arrangement. The locations of the open passages 122 and thetabs 120 should be equally spaced along the flange 110. In someexamples, three or more tabs with corresponding three or more openpassages are provided on the flange at equally spaced intervals. Thestamped housing section 100 is suited for mass production and aconnector housing is readily formed by combining two of such housingsections 100, as discussed below with reference to FIG. 1C.

FIG. 1B is a schematic side view of the housing section 100 of FIG. 1A.As shown, the skirt section 112 projects away from the upper flange 110.The projection may be referred to as an enlarged body portion 134extending outwardly from the flange 110. The enlarge body portion 134has an outer dimension that is smaller than the outer perimeter 104. Thehousing 100 is understood to have at least two tabs 120 extending awayfrom the upper flange 110. Still further, the housing 100 is understoodto have a flange defining a plane, at least two tabs extending away fromthe plane and an enlarged body portion extending away from the plane. Ina specific example, the tabs and the enlarged body portion extend awayfrom one another.

With reference again to FIG. 1C, a connector housing 130 is formed byattaching two housing sections 100 of FIG. 1A so that their operativesides 90 contact. The two housing sections 100 may be joined by firstplacing them in opposing contact and rotating one the housing sections100 so that the two tabs 120 of one housing section 100 align with thetwo open passages 122 of the other housing section 100 and then pressingthe two housing sections 100 together so that their respective upperflanges 110 abut, which causes the tabs 120 to project throughcorresponding open passages 122 in a slight interference fit. In otherexamples, the tabs 120 are slightly bent or deformed after projectingthrough the corresponding open passages 122 so as to form aninterference or press-fit. In still other examples, the two housingsections 100 are secured to one another by welding them along theinterface 136, such as with spot welds or laser welds. Foreseeably, thehousing sections may be practiced without any tabs 120 and the twohousing sections are simply welded together, such as with spot welds orcontinuous welds, to form a connector housing. An outer encapsulationsleeve or layer may also be used to capture and hold the two housingsections together instead of or in addition to mechanical engagementand/or welding.

As shown, the connector housing 130 is created by two separately formedhousing sections 100 that are subsequently attached together. In theexample shown, the two connector housing sections 100 are the same. Theconnector housing 130 has four mechanical connection points or joints138 (only two shown) formed by two tabs 120 of each housing section 100projecting into two corresponding open passages 122 of the opposinghousing section. In other examples, such as where three tabs and threeopen passages are incorporated in each housing section, there can bemore than four mechanical connection points 138. There can also be fewerthan four mechanical connection points or zero mechanical connectionpoint. For example, only one tab and one opening on each housing sectionto form two mechanical connection points can be provided for alignmentpurposes and to temporarily hold the two sections together with finalhousing connector more permanently secured by welding the interface 136using spot welds or laser welds. Optionally, only a single mechanicalconnection point 138 is used to temporarily hold the two housingsections together before welding to more permanently secure the two.

As shown, a housing groove 140 is formed by the two joined housingsections 100. Said differently, a groove 140 is formed by joining twostamped housing sections 100 together. In the present embodiment, thegroove 140 is formed by joining two identical housing sections together.In other examples, such as to from a non-symmetrical groove, twodifferent shaped housing sections are joined together to form a housinggroove. The groove 140 is generally V-shaped, such as a V-groove. Inother examples, by modifying the contour of the skirt section 112, theshape of the groove 140 may be altered. For example, the skirt section112 may be orthogonal to produce a flat bottom groove 140. In still yetother examples, two housing sections 100 for forming the connectorhousing 130 may not be identical and may have two different shaped orcontoured skirt sections 112 to form a non-symmetrical housing grooverelative to the interface line 136. Thus, the connector housing 130 maybe viewed as having a common bore 106, an interior cavity 132, and ahousing groove 140 formed without any machining to form the groove.Optionally, the surface of the skirt section 112 forming the groove maybe machined to further fine tune the groove 140 geometry. As shown, thegroove has a bottom wall 142 and two sidewalls 144 a, 144 b. In theembodiment shown, the bottom wall 142 has a parting line generally atthe middle of the groove. In yet other examples, if the housing sections100 are not symmetrical, the parting line of the groove may be offsetfrom center. As shown and excluding the tabs 120, the two housingsections are symmetrical about the interface 136. In other words, thetwo housing sections 100 may be understood to be formed from stampingand be symmetrical about the interface 136. Said differently, aconnector housing 130 can be provided by joining two symmetrical stampedhousing sections about an interface to form a housing groove 140. Aspreviously alluded to, the term stamped housing section does notpreclude some machining, such as to fine tune certain geometries of thehousing sections to fine tune the completed connector housing.

Exteriorly, a second groove 146 is provided at the interface 136. Thesecond groove 146 is formed by the tapered outwardly sections 110 b ofthe two upper flanges 110 of two adjacent housing sections 100. Theouter groove 146 may optionally be omitted by making the upper flanges110 generally planar or be modified, such as changing the contourthereof, by changing the shaped of the tapered outwardly sections 110 bor making one of the two sections flat. As shown, the outer groove isgenerally V-shaped and may be used to attach a lead or a cable thereto,such as for an electrical connector application.

With reference now to FIG. 1D, a canted coil spring 148 is shown locatedin the groove 146 of the connector housing 130, i.e., the spring ishousing mounted. The spring 148 may be an axial canted coil spring or aradial canted coil spring and each comprising a plurality of coilscanted in the same direction with each coil comprising a major axis anda minor axis. In other examples, the spring can be a garter spring, acantilever spring, or a ribbon spring. Exemplary canted coil springs aredisclosed in U.S. Pat. Nos. 4,655,462; 4,826,144; and 4,876,781, thecontents of which are expressly incorporated herein by reference. Thespring 148 is made from a conductive metal and may be plated or claddedwith one or more outer layers over a base metallic layer. As usedherein, conductive metal means any metal capable of conducting current,such as steel, stainless steel, copper, and gold. In certainembodiments, a preferred conductive metal, such as copper, copper alloy,or a preferred combination, such as copper with silver or other noblemetal cladding, may be used. For high temperature applications, a softbase metal may be used with a high tensile strength outer layer, such asa copper core with a stainless steel outer layer. In another example,the combination may be practiced in the reverse, i.e., with the hightensile strength material as the base core material and the highconductive property material, such as copper, as the cladding outerlayer. In still yet other examples, the high tensile strength propertymaterial can include heat treated carbon steel, INCONEL® alloys, andHASTELLOY® alloys. INCONEL alloys are understood to include a family ofnickel-chromium-based super alloys. HASTELLOY are understood to includea family of nickel based super alloys that include varying percentagesof elements such as molybdenum, chromium, cobalt, iron, manganese, etc.In an example, the second conductive clad layer having high conductivitycan include copper, copper alloy, aluminum, aluminum alloy, gold, goldalloy, silver, silver alloy, brass, or brass alloy. The combination witha high tensile strength base material and a conductive cladding materialis configured to offer high conductivity as well as retain high tensileand high modulus properties at elevated temperatures. The highconductivity layer is preferably positioned on the side of the springthat contacts or faces a pin (not shown). However, in anotherembodiment, the high tensile strength material can contact or face thepin.

As shown in FIG. 1D and further with reference to FIG. 1E, the innerdiameter 150 of the spring 148 is smaller than the diameter 152 of thebore 106 and smaller than the nominal diameter 42 of the pin 40. Thus,when the pin 40 is inserted in through the bore 106, the pin makescontact with the spring 148 and the spring is biased against the housinggroove 140 and the pin 40 to form a mechanical connector and optionallywith current or electric carrying capability, if connected to electricalsources. The pin 40 is shown with an exterior groove 44, such as for alatching or a locking application, or can be without a groove, such asfor a holding application. The housing groove 140 may have a width thatis narrower than the coil major axis so that the coils are rotated, suchas being constrained by the groove sidewalls, when positioned in thehousing groove. The housing groove width may also be wider than the coilmajor axis and/or the coil minor axis so that the coils do not touch thegroove sidewalls when placed therein. Still alternatively, the groovedepth may be such that the spring does not touch the groove bottomsurface 142 when the pin 40 is not inserted and wherein when the pin isinserted, the pin pushes on the spring to then contact the groovebottom. This feature allows for low insertion force.

The connector housing 130 and pin 40 combination, using the presentdisclosed stamped housing sections 100, is capable of being used innumerous applications and industries as mechanical connectors andoptionally with electrical carrying capabilities, i.e., as electricalconnectors. For example, the connector housing 130 with at least onestamped housing section and pin combination may be used in aerospace,automotive, consumer electronics, and oil and gas applications to securea first object to a second object or to conduct electricity, such ascurrent or signals, between two different sources or nodes.

During assembly, the spring 148 may be placed in the recessed space 120of the first housing section 100 and then the second housing section 100is attached to the first housing section. This allows the spring 148 tobe installed within the housing 130 with minimal deflection and stressto the spring, which in turn reduces the possibility of misorientationof the spring contact within the housing groove 140. In contrast to atypical prior art one-piece machined housing, the installation of aspring into the spring groove would require deflecting the spring asignificant amount to fit the spring through the housing bore diameterand then once through the bore diameter allow the spring to expand.However, this process can lead to the spring being tilted or misorientedwithin the groove upon expanding, thus possibly resulting in a highforce insertion or removal of the pin in through the bore of theone-piece housing, such as by having the pin contacting the springcloser to the major axis of the spring coils.

With reference again to FIG. 1E, the pin 40 is shown with a taperedinsertion end 46 and with a V-groove 44, which comprises two taperedwall surfaces 48 a, 48 b that converge towards the pin centerline. Thepin 40 can vary in length. In the particular embodiment shown, theV-groove 44 has a flat bottom wall 50. In other examples, the twotapered wall surfaces 48 a, 48 b converge to a point (i.e., no bottomwall). In still other examples, the two sidewalls 48 a, 48 b can begenerally parallel and the bottom wall is flat relative to the generallyparallel sidewalls or has a single taper relative to the two sidewalls.In yet other examples, one sidewall can be vertical while the other isslanted or tapered. The connector assembly 60 is understood to beconnectable to other components. For example, the pin may be connectedto a first object and the connector housing to a second object forsecuring the first object to the second object via the connectorassembly.

With reference now to FIG. 2A, a perspective view of an alternativehousing section 100 provided in accordance with aspects of the presentdevice, system, and method is shown. The alternative housing section 100is similar to the housing section 100 of FIGS. 1A-1C except for thefollowing features. In the present alternative embodiment, two tabs 160are shown with each tab 160 formed by providing two opposing cuts on theupper flange 110 and then cold extruding the surface layer 111 betweenthe two opposing cuts to form a projection-type tab 160. From a sideview of each tab 160, the tab has a generally V-shape with the ends ofthe V remaining in contact with the flange surface 111.

FIG. 2B is a side view of the housing section 100 of FIG. 2A.

FIG. 2C shows a connector housing 130 formed by attaching two housingsections 100 of FIG. 2A so that their operative sides 90 contact. As isreadily apparent, the two housing sections 100 may be joined by firstplacing them in opposing contact and turning or rotating one of thehousing sections 100 to align the two tabs 160 of one housing sectionwith the two open passages 122 of the other housing section 100 and thenpressing the two housing sections together so that their respectiveupper flanges 110 abut. The tabs 160 may form a slight interference fitwith their corresponding open passages 122. In other examples, the twohousing sections 100 are secured to one another by welding them alongthe interface 136, such as with spot welds or laser welds, in additionto the mechanical connection points 138. The connector housing 130 ofFIG. 2C is understood to include or have a canted coil spring positionedin the interior cavity 132 thereof before the two housing sections 100are combined or joined together. Optionally the spring may be placedinto the spring groove after the connector housing 130 is formed but itis not preferred.

With reference now to FIG. 3A, a perspective view of an alternativehousing section 100 provided in accordance with aspects of the presentdevice, system, and method is shown. The alternative housing section 100is similar to the housing section 100 of FIGS. 1A-1C except for thefollowing features. In the present alternative embodiment, two tabs 170are shown with each tab 170 formed by cold extruding the surface layer111 of the upper flange 110 with a blunt object, such as a blunt rod orpin, to form dome-shaped tabs. The tabs 170 each comprises a round base174 and a generally spherical top 176. The alternative housing section120 is also shown with two different open passages 172 for receiving thetwo tabs 170. As shown, the open passages 172 are generally round andsized to receive the corresponding tabs 170 in an interference fit.Optionally, the engagement is loose and the two housing sections arewelded together to more permanently secure them together.

FIG. 3B is a side view of the housing section 100 of FIG. 3A.

FIG. 3C shows a connector housing 130 formed by attaching two housingsections 100 of FIG. 3A so that their operative sides 90 contact. Thetwo housing sections 100 may be joined by first placing them in opposingcontact and turning or rotating one the housing sections 100 so that thetwo tabs 170 of one housing section 100 align with the two open passages172 of the other housing section 100 and then pressing the two housingsections together so that their respective upper flanges 110 abut. Thetabs 170 may form an interference fit with their corresponding openpassages 172. In other examples, the two housing sections 100 aresecured to one another by welding them along the interface 136, such aswith spot welds or laser welds, in addition to the mechanical connectionpoints or joints 138. The connector housing 130 of FIG. 3C is understoodto include or have a canted coil spring positioned in the interiorcavity 132 thereof before the two housing sections 100 are combined orjoined together.

With reference now to FIG. 4A, a perspective view of an alternativehousing section 100 provided in accordance with aspects of the presentdevice, system, and method is shown. The alternative housing section 100is similar to the housing section 100 of FIGS. 1A-1C except for thefollowing features. In the present alternative embodiment, two tabs 180are shown with each tab 180 formed by providing three cuts on the upperflange 110 and then cold extruding the surface layer 111, such asbending, the surface layer to form tabs. However, unlike the tabs 120 ofFIG. 1A, the tabs 180 of the present embodiment are orienteddifferently. For example, while the tabs 120 of FIG. 1A are connected atthe inside of the three-cuts for forming the tab, inside being radialinward towards the bore 106, the tabs 180 of the present embodiment arearranged differently. Only one tab 180 is similar to that of FIG. 1Awhile the other tab 180 is connected to the wall surface layer 111 alongan outer section, outer being radially outward closer to the perimeter104. The two tabs 180 can be said to be offset of one another. The openpassages have also been eliminated. Instead, the present housing section100 utilizes a combination tab/opening at each tab location to engage.

FIG. 4B is a side view of the housing section 100 of FIG. 4A.

FIG. 4C shows a connector housing 130 formed by attaching two housingsections 100 of FIG. 4A so that their operative sides 90 contact. As isreadily apparent, the two housing sections 100 may be joined by firstplacing them in opposing contact and turning or rotating one the housingsections 100 so that the two tabs 180 of one housing section 100 alignwith the two tabs 180 of the other housing section 100 and then pressingthe two housing sections together so that their respective upper flanges110 abut. The tabs 180 of one housing section 100, because of the offsetarrangement, align with two tabs 180 of the other housing section 100.The engagements have a slight interference fit with their correspondingtabs, such as by bending the tabs to rub against the openings. In otherexamples, the two housing sections 100 are secured to one another bywelding them along the interface 136, such as with spot welds or laserwelds, in addition to the mechanical connection points 138, with eachcomprising two tabs 180. The connector housing 130 of FIG. 4C isunderstood to include or have a canted coil spring positioned in theinterior cavity 132 thereof before the two housing sections 100 arecombined or joined together.

With reference now to FIG. 5A, a perspective view of an alternativehousing section 100 provided in accordance with aspects of the presentdevice, system, and method is shown. The alternative housing section 100is similar to the housing section 100 of FIGS. 1A-1C except for thefollowing features. In the present alternative embodiment, two 190 tabsare formed at the perimeter 104 with both tabs cold extruded to bend andpoint to the first side 90 while two additional tabs 192 are formed atthe perimeter 104 with both tabs cold extruded to bend and point to thesecond side 92 of the housing section 100. The four tabs 190, 192 areformed by making four cuts 194 at the perimeter 104 and bendingalternate sections of the surface layer 111 to point either to the firstside 90 or to the second side 92. Thus, the present housing section 100is understood to have two pairs of tabs 190, 192 formed at the perimeter104 of the housing section. For example, the tabs 190, 192 are formed bycutting the upper flange 110 so that the perimeter 104 of the upperflange comprises a plurality of cuts 194. As shown, the cuts areradially oriented. In other examples, the cuts can be slanted. In stillyet other examples, there can be more than four cuts, such as six cuts,to form six tabs, such as to form two sets of three tabs with the tabspointing to the first side 90 or to the second side 92.

FIG. 5B is a side view of the housing section 100 of FIG. 5A.

FIG. 5C shows a connector housing 130 formed by attaching two housingsections 100 of FIG. 5A so that their operative sides 90 contact. Thetwo housing sections 100 may be joined by first placing them in opposingcontact and turning or rotating one of the housing sections 100 so thatthe first set of two tabs 190 of one housing section 100 align with thesecond set of two tabs 192 of the other housing section 100 and thesecond set of two tabs 192 of one housing section 100 align with thefirst set of two tabs 190 of the other housing section 100. The twohousing sections 100 are then pushed together so that their respectiveupper flanges 110 abut. The tabs 190, 192 of one housing section 100,because of the offset arrangement, align with the tabs 190, 192 of theother housing section 100. The connection may be a simple contact tolimit relative rotation between the two housing sections. In otherexamples, the two housing sections 100 are secured to one another bywelding them along the interface 136, such as with spot welds or laserwelds. The connector housing 130 of FIG. 5C is understood to include orhave a canted coil spring positioned in the interior cavity 132 thereofbefore the two housing sections 100 are combined or joined together. Instill other examples, as discussed above, an encapsulation layer may beused to hold the two housing sections 100 together with a springtherebetween.

With reference now to FIG. 6A, a perspective view of an alternativehousing section 100 provided in accordance with aspects of the presentdevice, system, and method is shown. The alternative housing section 100is similar to the housing section 100 of FIGS. 1A-1C except for thefollowing features. In the present alternative embodiment, no engagementtabs and no open passages are incorporated on the upper flange 200.Instead, as further discussed below, the upper flange 200 is configuredto mate or abut against a flat surface, with no mechanical engagement.The upper flange 200 is relatively narrower than the upper flange 110 ofFIG. 1A and noticeably flatter in profile, as shown in FIG. 6B. Thus,the outer perimeter 104 of the upper flange 200 is situated closer tothe inside perimeter 118 of the recessed space 120. As with the otherconnector housing sections 100, the gap between the surface 202 of theupper flange 200 and the surface 204 of the lower flange 114 may beadjusted depending to the type and/or size of the spring to beaccommodated. Similarly, the skirt section 112, while shown with ataper, may be adjusted to have a generally flat surface, i.e., generallyorthogonal to the surface 202 of the upper flange 200. Furthermore,while the two surfaces 202, 204 of the two flanges are generallyparallel, the surface 204 of the lower flange 204 may be slightlytapered to produce a housing groove with a tapered sidewall.

FIG. 7 is a cross-sectional side view of a connector housing 210provided in accordance with aspects of the present device, system, andmethod. As shown, the connector housing 210 comprises a housing section100, such as the one shown in FIG. 6A, abutted against a housing backingflange 212 comprising a body 214 comprising an opening 215 and a bore216 having an inside diameter 218. In one example, the housing backingflange 212 is made from a conductive material and is attached to thehousing section 100 by welding. In another example, the housing backingflange 212 is made from an engineered plastic and is attached to thehousing section 100 by high temperature resistant bonding. In anotherexample, the backing flange 212 has open passages for receiving tabsextending from the housing section 100, similar to the tabs shown inFIGS. 1A-4C. The backing flange 212 may be machined or cast or may bestamped from a blank to form the bore 216. Thus, the connector housing210 has at least one stamped housing section 100 and is non-symmetrical.If the housing backing flange 212 is also stamped, then the entireconnector housing 210 may have two stamped housing sections but isnon-symmetrical about an interface between the two housing sections 100,212.

As shown, the housing connector 210 comprises a housing groove 140 witha tapered bottom wall 142 and two generally parallel sidewalls 144 a,144 b, including a first side 90 and a second side 92. The first side 90of the housing flange 212 contacts the first side 90 of the stampedhousing section 100. The groove is sized and shaped to accommodate acanted coil spring 148, which is shown as an axial canted coil springwith a radial canted coil spring contemplated. While only two coils areshown, the canted coil spring 148 is understood to include a pluralityof coils all canted in the same direction and all comprising a majoraxis and a minor axis. Furthermore, it is understood that the springwill only deflect in the canting direction along the minor axis but notthe major axis. The spring 148 has an inside diameter 150 that issmaller than the ID 108 of the housing section and the ID 218 of thebore of the housing backing flange 212. The connector housing 210 andspring 148 are configured to receive a pin (not shown) having a pin ODthat is larger than the spring ID so that the spring is biased by thepin and the housing 210. As discussed elsewhere herein, the pin may havean external groove to latch or lock the pin relative to the housing,such as by capturing the spring in between the housing groove and thepin groove, or without an external groove to hold the pin to thehousing, such as by using spring bias force or push against the flatexterior surface of the pin to hold the pin using friction and biasingforces. The pin (not shown) preferably includes a tapered pin insertionend to facilitate inserting the pin into the bore of the connectorhousing and through the inside diameter of the spring. Exemplary use ofholding, latching, and locking connectors but without the unique housingconnectors and grooves utilizing stamped connector parts are disclosedin U.S. Pat. No. 4,678,210; 5,082,390; 5,411,348; and 8,297,662, thecontents of which are expressly incorporated herein by reference. Any ofthe various pins disclosed in these patents may be used with theconnector housings of the present disclosure.

With reference now to FIG. 8, a schematic cross-sectional side view ofyet another connector housing 220 provided in accordance with aspects ofthe present device, system, and method is shown. The connector housing220 is shown with an external groove 222 formed by placing two stampedhousing sections 100 back-to-back. More specifically, the housingconnector 220 is formed by placing the second side 92 of two housingsections 100 together to form the exterior groove 222 comprising agroove bottom 142 and two sidewalls 144 a, 144 b. In practice, thespring 148 is placed over the outside skirt section 112 of one stampedhousing section 100 before placing the second housing section 100 inabutting contact with the first. This will allow the spring 148 to bepositioned on the connector housing 220 without having to expand thespring inside diameter to mount the spring over the perimeter 104 of thegroove 222. The two housing sections 100 may be secured together to formthe connector housing 220 using any known means, including welding,bonding, detents, tabs, set screws, etc.

The connector housing 220 is configured for use with or inside a bore(not shown), such as for inserting the connector housing 220, includingthe spring 148, inside the bore of a housing. The common bore 106 of thetwo housing sections 100 are configured to receive a pin, which is to befitted with one or two adaptors (not shown) having an outside contourfor mating or matching with the recessed space 120. In another example,two separate shaft sections (not shown) each with an end sized andshaped to couple with the recessed space 120 of each housing section100. In other words, the connector housing 220 may be viewed as formingpart of an exterior groove of a pin, such as by forming two separate pinsections to attach to the connector housing 220. The perimeter 104 ofthe two housing sections 100 therefore represents the nominal outsidediameter of the pin having the connector housing 220 of FIG. 8 as theexterior pin groove. Again, by modifying the skirt section of one orboth housing sections 100, the pin groove geometry may be altered, suchas to have a flat bottom wall, a single slope bottom wall, taperedsidewalls, generally parallel sidewalls, a narrow width to touch thespring, a wide width to not touch the spring with the sidewalls, a deepgroove to not touch the spring with the bottom wall, etc.

With reference now to FIG. 9A, an implantable medical device 230comprising a can housing 240, a header 242, and an in-line connectorstack 242 comprising a plurality of connector components having a commonbore for receiving a lead cable 244 is shown. Exemplary IMDs, such asimplantable cardio defibrillators, pacemakers, and programmableneuro-stimulator pulse generators are herein referred to as “implantablemedical devices” or IMDs. IMDs and in-line connectors are disclosed inU.S. Pat. No. 8,437,855, the contents of which are expresslyincorporated herein by reference. The can housing 240 is a hermeticallysealed device enclosing a power source and electronic circuitry forpassing signals to the lead cable via the in-line connector 242.

FIG. 9B is an enlarged cross-sectional side view of the header 242 ofFIG. 9A. As shown, the header has a bore 248 for receiving the in-lineconnector stack 242, which comprises a plurality of seal elements 250,conductive contact elements 252, and springs 148. The seal elements 250are each configured to seal against the bore 248 of the header 242 andagainst the exterior surface of the lead cable 246. The spring contacts148 are configured to bias against the electrical terminals 254 of thelead cable 246 to pass signals or current from inside the can housing240, through the conductive contact elements 252, through the springs148, to the electrical terminals 254, and to the electrode leads (notshown) located inside the lead cable 246 and extending to the variousparts of the human body to provide electrical stimulation to the bodytissues.

As shown, the various conductive contact elements 252 and springsutilized in the header 242 may be any one of the various connectorhousings and springs discussed elsewhere herein. Thus, the conductivecontact elements 252 are each understood to be formed by joining twostamped housing sections 100 to form a housing groove for accommodatinga spring 148 without any or without substantial machining to form thehousing groove. The conductive contact elements 252 may each furtherinclude tapered outer shoulders formed by the skirt sections 112 of thestamped housing sections for sealing against, such as abutting, ashoulder of an adjacent seal element 250. Also shown in FIG. 9B is aholding ring 256 comprising a set screw 258 securing against therecessed section 260 of the lead cable 246 to secure the lead cable tothe header.

FIG. 10A is a schematic partial cross-sectional partial side view of anin-line connector stack 270 comprising a plurality of connectorcomponents located inside an encapsulation layer 272, which isconfigured to retain or hold the in-line connector stack 270 away oroutside of a header, for example the header 242 of FIGS. 9A and 9B. Theencapsulated stack 274, which comprises the encapsulation layer 272surrounding and retaining the in-line connector stack 270 outside of aheader, is also shown with a mounting pin 276, which resembles the leadcable of FIG. 9B except it is solid and does not carry electrode leads.The mounting pin facilitates stacking of the various components forassembling purposes. The encapsulated stack 274 is assembled with aplurality of alternating seal elements 250 and conductive contactelements 252 each comprising a spring contact element 148 to form thein-line connector stack. The conductive contact elements 252 resembleone of the connector housings discussed elsewhere herein made from atleast two stamped housing sections 100.

The encapsulated stack 274 allows the integrity of the in-line stack 270to be tested outside of a header and before it is installed in an IMD.For example, conductive leads 278 may be attached to correspondingconductive contact elements 252 through windows 280 provided through theencapsulation layer 272, such as by welding or soldering the leads 278to the interface 136 of the conductive contact elements 252 of twoadjacent housing sections 100. Thus, the windows 280 on theencapsulation layer 272 as well as the conductor leads 278 are alignedwith corresponding interfaces 136 of two adjacent housing elements 100.Test current or signals may be applied through the conductor leads 278to test the operability of the in-line connector 270, such as to testcurrent sent to the conductive contact housing 252 via the conductorleads. The stack can also be tested by holding the components that formthe housing together with the spring contacts installed in the housingand inserting a lead to find insertion, removal, and frictional forces,and electrical performance. Exemplary encapsulated stacks andencapsulation layers but without the unique stamped features of thepresent device, system, and method are disclosed in U.S. Pat. No.8,215,013, the contents of which are expressly incorporated herein byreference.

FIG. 10B is a cross-sectional end view of the encapsulated stack 274 ofFIG. 10A taken along line 10B-10B.

FIGS. 10C and 10D are blown up views of the encapsulated stack of FIG.10A to show the various interference fit. For example, comparing theseal element 250 of FIG. 10C versus that of FIG. 10D, the outer sealsection or shoulder 290 has a larger outside dimension than the insidediameter of the encapsulated layer 272. Similarly, the annularprojection or lip 282 on the seal element 250 has a smaller insidediameter than the outside diameter of the installation pin 276, whichhas the approximately the same outside diameter as a lead cable (See,e.g., “246”) of FIG. 9B. Thus, when installed, a seal is providedbetween the interface of the encapsulated layer and each seal elementand the installation pin 276 and each sealing lip 292. Note that theseal lip 292 is positioned between two undercuts 294 formed in the boreof the seal element 250 to reduce the insertion force of the pin. Theundercuts allow space for the seal lip to deflect, such as to reduce itstotal bending moment. Similarly, the inside diameter of the spring 148is smaller than the pin outside diameter. Upon insertion of the pin, thespring will cant or deflect due to the relative sizes. Exemplary sealelements with undercuts to reduce insertion force are disclosed in EPapplication No. 09826890.7, which derived from PCT application No.PCT/US2009064527, the contents of which are expressly incorporatedherein by reference.

FIG. 10D shows the same view but with the various components deflecteddue to the geometries of the various components.

FIG. 11A is a perspective view of the connector stack 242 or 270 of FIG.9B or 10A but without an encapsulation layer or a header to better showthe various connector components 250, 252, 278. As shown, there areeight conductor leads 278 and eight conductive contact elements 252. Inother examples, there can be more than or fewer than eight conductorleads 278 and eight conductive contact elements 252.

FIG. 11B is an enlarged view of one of the connection points between theconductor lead 278 and one of the conductive contact elements 252. Asshown, the conductor lead 278 is welded along an interface 136 of twoadjacent stamped housing sections 100 of a conductive contact element252.

Although limited embodiments of the housing sections, connectorhousings, and IMDs and their components have been specifically describedand illustrated herein, many modifications and variations will beapparent to those skilled in the art. Furthermore, elements and featuresexpressly discussed for one embodiment but not for another may equallyapply provided the functionality or structures do not conflict. Thus,unless the context indicates otherwise, like features for one embodimentare applicable to another embodiment. Accordingly, it is to beunderstood that the housing sections, connector housings, and IMDs andtheir components constructed according to principles of the discloseddevice, system, and method may be embodied other than as specificallydescribed herein. The disclosure is also defined in the followingclaims.

What is claimed is:
 1. A method for making a connector housing, themethod comprising: forming by stamping a first housing section orforming by plastic injection molding a first housing section, said firsthousing section comprising an upper flange with an outer perimeter, alower flange, and a skirt section located between the upper flange andthe lower flange, and said lower flange having a perimeter defining anopening; forming by stamping a second housing section or forming byplastic injection molding a second housing section, said second housingsection comprising an upper flange with an outer perimeter, a lowerflange, and a skirt section located between the upper flange and thelower flange, and said lower flange having a perimeter defining anopening; attaching said first housing section to said second housingsection by abutting said two upper flanges to form a connector housingcomprising a bore with the opening of the first housing section at afirst end of the bore and the opening of the second housing section at asecond end of the bore, and a housing groove comprising a groove bottomformed by the first housing section and the second housing section; andplacing spring inside the housing groove.
 2. The method of claim 1,wherein the spring is a canted coil spring, a garter spring, acantilever spring, or a ribbon spring.
 3. The method of claim 1, whereinthe first housing is stamped from a material made from steel, stainlesssteel, copper, gold, MP35N, platinum-iridium, or titanium.
 4. The methodof claim 1, wherein said skirt section of said first housing section andsaid skirt section of said second housing section form said groovebottom with two tapered surfaces having an interface locatedtherebetween.
 5. The method of claim 1, wherein the first housingsection has a path for terminating an electrical lead.
 6. The method ofclaim 1, wherein an interface between the first housing section and thesecond housing section is generally orthogonal to an axis passingthrough the common bore.
 7. The method of claim 1, wherein the firsthousing section is made from a multi-layer material with a base metallayer and one or more cladding or plating over layers
 8. The method ofclaim 1, further comprising abutting a canted coil spring against theskirt section of the first housing section and against the skirt sectionof the second housing section.
 9. The method of claim 8, wherein thecanted coil spring has a smaller inside diameter than diameters of thetwo openings of the bore.
 10. The method of claim 9, further comprisingthe step of projecting a pin through the bore.
 11. The method of claim19, wherein the pin has a groove and the spring is located in the grooveof the pin.
 12. The method of claim 1, wherein the first housing sectionis attached to the second housing section by welding, bonding, usingtabs, using detents, or using set screws.
 13. A method for making aconnector assembly, the method comprising: forming by stamping a firsthousing section or forming by plastic injection molding a first housingsection, said first housing section comprising a skirt section, an upperflange extending radially outwardly from the skirt section and having anouter perimeter, and a lower flange extending radially inward from theskirt section and comprising a perimeter defining an opening; forming bystamping a second housing section or forming by plastic injectionmolding a second housing section, said second housing section comprisinga perimeter defining an opening; forming a connector housing with ahousing groove by abutting the first housing section and the secondhousing section at an interface and wherein the openings of the firsthousing section and the second housing section define a common bore;placing a spring in the housing groove; and securing the first andsecond housing sections together by welding, bonding, using tabs, usingdetents, or using set screws.
 14. The method of claim 13, furthercomprising projecting a tab extending from the first housing sectionthrough an opening of the second housing section.
 15. The method ofclaim 13, wherein the spring is a canted coil spring, a garter spring, acantilever spring, or a ribbon spring
 16. The method of claim 13,wherein the first housing is stamped from a material made from steel,stainless steel, copper, gold, MP35N, platinum-iridium, or titanium. 17.The method of claim 13, wherein the opening of the first housing sectiondefines a plane and wherein housing groove has a bottom that isorthogonal to the plane or tapered relative to the plane.
 18. The methodof claim 13, further comprising projecting a pin through the commonbore.
 19. The method of claim 13, wherein the first housing section hasa path for terminating an electrical lead.
 20. The method of claim 13,wherein the first housing section is made from a multi-layer materialwith a base metal layer and one or more cladding or plating over layers.